Download BoosterpaQ Hydro MPC-F Guide Specification

BoosterpaQ Hydro MPC-F Guide Specification
Part I – GENERAL
1.1
WORK INCLUDED
A. Variable Speed Packaged Pumping System
1.2
REFERENCE STANDARDS
The work in this section is subject to the requirements of applicable portions of the following
standards:
A.
B.
C.
D.
E.
F.
G.
H.
Hydraulic Institute
ANSI – American National Standards Institute
ASTM – American Society for Testing and Materials
IEEE – Institute of Electrical and Electronics Engineers
NEMA – National Electrical Manufacturers Association
NEC – National Electrical Code
ISO – International Standards Organization
UL – Underwriters Laboratories, Inc.
Part 2 – PRODUCTS
2.1
VARIABLE SPEED PACKAGED PUMPING SYSTEM
A. Furnish and install a pre-fabricated and tested variable speed packaged pumping system to
maintain constant water delivery pressure.
B. The packaged pump system shall be a standard product of a single pump manufacturer. The
entire pump system including pumps and pump logic controller, shall be designed and built by the
same manufacturer.
C. The complete packaged water booster pump system shall be certified and listed by UL (Category
QCZJ – Packaged Pumping Systems) for conformance to U.S. and Canadian Standards.
2.2
PUMPS
A. All pumps shall be ANSI/NSF 61 approved for drinking water.
B. The pumps shall be of the in-line vertical multi-stage design.
C. The head-capacity curve shall have a steady rise in head from maximum to minimum flow within
the preferred operating region. The shut-off head shall be a minimum of 20% higher than the
head at the best efficiency point.
D. Small Vertical In-Line Multi-Stage Pumps (Nominal flow from 3 to 125 gallons per minute) shall
have the following features:
1.
The pump impellers shall be secured directly to the pump shaft by means of a splined shaft
arrangement.
2.
The suction/discharge base shall have ANSI Class 250 flange or internal pipe thread (NPT)
connections as determined by the pump station manufacturer.
3.
Pump Construction.
BoosterpaQ Hydro MPC F Guide Specification, Page 1 of 9
a.
b.
c.
d.
e.
f.
Suction/discharge base, pump head, motor stool:
Impellers, diffuser chambers, outer sleeve:
Shaft
Impeller wear rings:
Shaft journals and chamber bearings:
O-rings:
Cast iron (Class 30)
304 Stainless Steel
316 or 431 Stainless Steel
304 Stainless Steel
Silicon Carbide
EPDM
Shaft couplings for motor flange sizes 184TC and smaller shall be made of cast iron or
sintered steel. Shaft couplings for motor flange sizes larger than 184TC shall be made of
ductile iron (ASTM 60-40-18).
Optional materials for the suction/discharge base and pump head shall be cast 316 stainless
steel (ASTM CF-8M) resulting in all wetted parts of stainless steel.
4.
The shaft seal shall be a balanced o-ring cartridge type with the following features:
a.
b.
c.
d.
e.
Collar, Drivers, Spring:
Shaft Sleeve, Gland Plate:
Stationary Ring:
Rotating Ring:
O-rings:
316 Stainless Steel
316 Stainless Steel
Silicon Carbide
Silicon Carbide
EPDM
The Silicon Carbide shall be imbedded with graphite.
5.
Shaft seal replacement shall be possible without removal of any pump components other
than the coupling guard, shaft coupling and motor. The entire cartridge shaft seal shall be
removable as a one piece component. Pumps with motors equal to or larger than 15 hp
(fifteen horsepower) shall have adequate space within the motor stool so that shaft seal
replacement is possible without motor removal.
E. Large In-line Vertical Multi-Stage Pumps (Nominal flows from 130 to 500 gallons per minute) shall
have the following features:
1.
The pump impellers shall be secured directly to the smooth pump shaft by means of a split
cone and nut design.
2.
The suction/discharge base shall have ANSI Class 125 or Class 250 flange connections in a
slip ring (rotating flange) design as indicated in the drawings or pump schedule.
3.
Pump Construction.
a.
b.
b.
c.
d.
e.
f.
g.
h.
I.
4.
Suction/discharge base, pump head
Shaft couplings, flange rings:
Shaft
Motor Stool
Impellers, diffuser chambers, outer sleeve:
Impeller wear rings:
Intermediate Bearing Journals:
Intermediate Chamber Bearings:
Chamber Bushings:
O-rings:
Ductile Iron (ASTM 65-45-12)
Ductile Iron (ASTM 65-45-12)
431 Stainless Steel
Cast Iron (ASTM Class 30)
304 Stainless Steel
304 Stainless Steel
Tungsten Carbide
Leadless Tin Bronze
Graphite Filled PTFE
EPDM
The shaft seal shall be a single balanced metal bellows cartridge with the following
construction:
a.
b.
c.
d.
Bellows:
Shaft Sleeve, Gland Plate, Drive Collar:
Stationary Ring:
Rotating Ring:
904L Stainless Steel
316 Stainless Steel
Carbon
Tungsten Carbide
BoosterpaQ Hydro MPC F Guide Specification, Page 2 of 9
e. O-rings:
5.
2.3
EPDM
Shaft seal replacement shall be possible without removal of any pump components other
than the coupling guard, motor couplings, motor and seal cover. The entire cartridge shaft
seal shall be removable as a one piece component. Pumps with motors equal to or larger
than 15 hp (fifteen horsepower) shall have adequate space within the motor stool so that
shaft seal replacement is possible without motor removal.
VARIABLE FREQUENCY DRIVE
A. The VFD shall convert incoming fixed frequency single-phase or three-phase AC power into a
variable frequency and voltage for controlling the speed of three-phase AC induction motors. The
VFD shall be a six-pulse input design, and the input voltage rectifier shall employ a full wave
diode bridge; VFD’s utilizing controlled SCR rectifiers shall not be acceptable. The output
waveform shall closely approximate a sine wave. The VFD shall be of a PWM output design
utilizing current IGBT inverter technology and voltage vector control of the output PWM
waveform.
B. The VFD shall include a full-wave diode bridge rectifier and maintain a displacement power factor
of near unity regardless of speed and load.
C. The VFD shall produce an output waveform capable of handling maximum motor cable distances
of up to 1,000 ft. (unshielded) without tripping or derating.
D. The VFD shall utilize an output voltage-vector switching algorithm, or equivalent, in both variable
and constant torque modes. VFD’s that utilize Sine-Coded PWM or Look-up tables shall not be
acceptable.
E. VFD shall automatically boost power factor at lower speeds.
F. The VFD shall be able to provide its full rated output current continuously at 110% of rated
current for 60 seconds.
G. An empty pipe fill mode shall be available to fill an empty pipe in a short period of time, and then
revert to the PID controller for stable operation.
H. Switching of the input power to the VFD shall be possible without interlocks or damage to the
VFD at a minimum interval of 2 minutes.
I.
Switching of power on the output side between the VFD and the motor shall be possible with no
limitation or damage to the VFD and shall require no additional interlocks.
J.
The VFD shall have temperature controlled cooling fans for quiet operation, minimized internal
losses, and greatly increased fan life.
K. VFD shall provide full torque to the motor given input voltage fluctuations of up to +10% to -15%
of the rated input voltage.
L. The VFD shall provide internal DC link reactors to minimize power line harmonics and to provide
near unity power factor. VFD’s without a DC link reactor shall provide a 5% impedance line side
reactor.
M. VFD to be provided with the following protective features:
1. VFD shall have input surge protection utilizing MOV’s, spark gaps, and Zener diodes
to withstand surges of 2.3 times line voltage for 1.3 msec.
2. VFD shall include circuitry to detect phase imbalance and phase loss on the input
side of the VFD.
BoosterpaQ Hydro MPC F Guide Specification, Page 3 of 9
3. VFD shall include current sensors on all three-output phases to detect and report
phase loss to the motor. The VFD will identify which of the output phases is low or
lost.
4. VFD shall auto-derate the output voltage and frequency to the motor in the presence
of sustained ambient temperatures higher than the normal operating range, so as not
to trip on an inverter temperature fault. The use of this feature shall be userselectable and a warning will be exported during the event. Function shall reduce
switching frequency before reducing motor speed.
5. VFD shall auto-derate the output frequency by limiting the output current before
allowing the VFD to trip on overload. Speed can be reduced, but not stopped.
6. The VFD shall have the option of an integral RFI filter. VFD enclosures shall be made
of metal to minimize RFI and provide immunity.
N. VFD to be provided with the following interface features:
1. VFD shall provide an alphanumeric backlit display keypad, which may be remotely
mounted using standard 9-pin cable. VFD may be operated with keypad
disconnected or removed entirely. Keypad may be disconnected during normal
operation without the need to stop the motor or disconnect power to the VFD.
2. VFD shall display all faults in plain text; VFD’s, which can display only fault codes,
are not acceptable.
3. All VFD’s shall be of the same series, and shall utilize a common control card and
LCP (keypad/display unit) throughout the rating range. The control cards and
keypads shall be interchangeable through the entire range of drives used on the
project.
4. VFD keypad shall be capable of storing drive parameter values in non-volatile RAM
uploaded to it from the VFD, and shall be capable of downloading stored values to
the VFD to facilitate programming of multiple drives in similar applications, or as a
means of backing up the programmed parameters.
5. A red FAULT light, a yellow WARNING light and a green POWER-ON light shall be
provided. These indications shall be visible both on the keypad and on the VFD when
the keypad is removed.
6. A start guide menu with factory preset typical parameters shall be provided on the
VFD to facilitate commissioning.
7. VFD shall provide full galvanic isolation with suitable potential separation from the
power sources (control, signal, and power circuitry within the drive) to ensure
compliance with PELV requirements and to protect PLC’s and other connected
equipment from power surges and spikes.
8. All inputs and outputs shall be optically isolated. Isolation boards between the VFD
and external control devices shall not be required.
9. There shall be three programmable digital inputs for interfacing with the systems
external control and safety interlock circuitry. An additional digital input is
preprogrammed for start/stop.
10. The VFD shall have two analog signal inputs. One dedicated for sensor input and
one for external set point input.
11. One programmable analog output shall be provided for indication of a drive status.
12. The VFD shall provide two user programmable relays with selectable functions. Two
form ‘C’ 230VAC/2A rated dry contact relay outputs shall be provided.
BoosterpaQ Hydro MPC F Guide Specification, Page 4 of 9
13. The VFD shall store in memory the last 5 faults with time stamp and recorded data.
14. The VFD shall be equipped with a standard RS-485 serial communications port for
communication to the multi-pump controller. The bus communication protocol for the
VFD shall be the same as the controller protocol.
O. VFD service conditions:
1. Ambient temperature operating range, -10 to 45ºC (14 to 113F).
2. 0 to 95% relative humidity, non-condensing.
3. Elevation to 1000 meters (3,300 feet) without derating.
4. VFD’s shall be rated for line voltage of 525 to 690VAC, 380 to 480VAC, or 200 to
240VAC; with +10% to -15% variations. Line frequency variation of ± 2% shall be
acceptable.
5. No side clearance shall be required for cooling of the units.
2.4
FIXED SPEED MOTORS
A. Fixed Speed Motors are to be provided with the following basic features:
2.5
1.
Designed for continuous duty operation, NEMA design B with a 1.15 service factor.
2.
Totally Enclosed Fan Cooled or Open Drip Proof with Class F insulation.
3.
Nameplate shall have, as a minimum, all information as described in NEMA Standard MG 120.40.1.
4.
Motors shall have a NEMA C-Flange for vertical mounting.
5.
Drive end bearings shall be adequately sized so that the minimum L10 bearing life is 17,500
hours at the minimum allowable continuous flow rate for the pump.
PUMP SYSTEM CONTROLLER
A. The pump system controller shall be a standard product developed and supported by the pump
manufacturer.
B. The controller shall be microprocessor based capable of having software changes and updates
via personal computer (notebook). The controller user interface shall have a VGA display with a
minimum screen size of 3-1/2” x 4-5/8” for easy viewing of system status parameters and for field
programming. The display shall have a back light with contrast adjustment. Password protection
of system settings shall be standard.
C. The controller shall provide internal galvanic isolation to all digital and analog inputs as well as all
fieldbus connections.
D. The controller shall display the following as status readings from a single display on the controller
(this display shall be the default):




Current value of the control parameter, (typically discharge pressure)
Most recent existing alarm (if any)
System status with current operating mode
Status of each pump with current operating mode and rotational speed as a percentage (%)
BoosterpaQ Hydro MPC F Guide Specification, Page 5 of 9
E. The controller shall have as a minimum the following hardware inputs and outputs:





Three analog inputs (4-20mA or 0-10VDC)
Three digital inputs
Two digital outputs
Ethernet connection
Field Service connection to PC for advanced programming and data logging
F. Pump system programming (field adjustable) shall include as a minimum the following:









Water shortage protection (analog or digital)
Transducer Settings (Suction and Discharge Analog supply/range)
PI Controller (Proportional gain and Integral time) settings
High system pressure indication and shut-down
Low system pressure indication and shut-down
Low suction pressure/level shutdown (via digital contact)
Low suction pressure/level warning (via analog signal)
Low suction pressure/level shutdown (via analog signal)
Flow meter settings (if used, analog signal)
G. The system controller shall be able to accept up to seven programmable set-points via a digital
input, (additional input/output module may be required).
H. The controller shall have advanced water shortage protection. When analog sensors (level or
pressure) are used for water shortage protection, there shall be two indication levels. One level is
for warning indication only (indication that the water level/pressure is getting lower than expected
levels) and the other level is for complete system shut-down (water or level is so low that pump
damage can occur). System restart after shut-down shall be manual or automatic (user
selectable).
I.
The system pressure set-point shall be capable of being automatically adjusted by using an
external set-point influence. The set-point influence function enables the user to adjust the
control parameter (typically pressure) by measuring an additional parameter. (Example: Lower
the system pressure set-point based on a flow measurement to compensate for lower friction
losses at lower flow rates).
J.
The controller shall be capable of receiving a remote analog set-point (4-20mA or 0-10 VDC) as
well as a remote system on/off (digital) signal.
K. The pump system controller shall store up to 24 warning and alarms in memory. The time, date
and duration of each alarm shall be recorded. A potential-free relay shall be provided for alarm
notification to the building management system. The controller shall display the following alarm
conditions:
High System Pressure
Low suction pressure (warning and/or alarm)
VFD trip/failure
Loss of remote set-point signal (4-20mA)
Low system pressure
Individual pump failure
Loss of sensor signal (4-20 mA)
System power loss
L. The pump system controller shall be mounted in a UL Type 3R rated enclosure. A self-certified
NEMA enclosure rating shall not be considered equal. The entire control panel shall be UL 508
listed as an assembly. The control panel shall include a main disconnect, circuit breakers for
each pump and the control circuit and control relays for alarm functions.
Control panel options shall include, but not be limited to:
Pump Run Lights
Pump Alarm Lights
BoosterpaQ Hydro MPC F Guide Specification, Page 6 of 9
System Fault Light
Surge Arrestor
Emergency/Normal Operation Switches
Audible Alarm (80 db[A])
Control Panel Internal Illumination
Service Disconnect Switches
M. The controller shall be capable of receiving a redundant sensor input to function as a backup to
the primary sensor (typically discharge pressure).
N. The controller shall have a pump “Test Run” feature such that pumps are switched on during
periods of inactivity (system is switched to the “off” position but with electricity supply still
connected). The inoperative pumps shall be switched on for a period of two to three (2-3)
seconds every 24 hours, 48 hours or once per week (user selectable).
O. The actual pump performance curves (5th order polynomial) shall be loaded (software) into the
pump system controller.
2.6
SEQUENCE OF OPERATION
The system controller shall operate from two to six equal capacity pumps and one Variable
Frequency Drive (VFD) to maintain a constant discharge pressure (system set-point). The
system controller shall receive an analog signal [4-20mA] from the factory installed pressure
transducer on the discharge manifold, indicating the actual system pressure. When a flow
demand is detected (drop in system pressure) the VFD controlled pump shall start first. As flow
demand increases, the speed of the VFD controlled pump shall be increased to maintain the
system set-point pressure. When the VFD controlled pump cannot maintain the system set-point
as flow increases (pressure starts to drop below system set-point), an additional pump will be
started Direct-On-Line (DOL). The VFD controlled pump shall immediately adjust speed to
maintain the system set-point. Additional DOL pumps shall be started as flow demand increases.
As flow demand decreases, the pump speed shall be reduced while system set-point pressure is
maintained. The system controller shall switch off DOL operated pumps as required with
decreasing flow.
The system controller shall be capable of switching pumps on and off to satisfy system demand
without the use of flow switches, motor current monitors or temperature measuring devices.
2.7
LOW FLOW STOP FUNCTION
The system controller shall be capable of stopping pumps during periods of low-flow or zero-flow
without wasting water or adding unwanted heat to the liquid. Temperature based no flow shutdown methods that have the potential to waste water and add unwanted temperature rise to the
pumping fluid are not acceptable.
Standard Low Flow Stop and Energy Saving Mode
If a low or no flow shut-down is required (periods of low or zero demand) a bladder type
diaphragm tank shall be installed with a pre-charge pressure of 70% of system set-point. The
tank shall be piped to the discharge manifold or system piping downstream of the pump system.
When only one pump is in operation the system controller shall be capable of detecting low flow
(less than 10% of pump nominal flow) without the use of additional flow sensing devices. When a
low flow is detected, the system controller shall increase pump speed until the discharge pressure
reaches the stop pressure (system set-point plus 50% of programmed on/off band). The pump
shall remain off until the discharge pressure reaches the start pressure (system set-point minus
50% of programmed on/off band). Upon low flow shut-down a pump shall be restarted in one of
the following two ways:
a. Low Flow Restart: If the drop in pressure is slow when the start pressure is reached
(indicating the flow is still low), the pump shall start and the speed shall again be
increased until the stop pressure is reached and the pump shall again be switched off.
BoosterpaQ Hydro MPC F Guide Specification, Page 7 of 9
b. Normal Flow Restart: If the drop in pressure is fast (indicating the flow is greater than
10% of pump nominal flow) the pump shall start and the speed shall be increased until
the system pressure reaches the system set-point.
[OPTIONAL] Low Flow Stop and Energy Saving Mode
The pump system controller shall be capable receiving a digital signal from a flow switch or
an analog signal from a flow meter to indicate a low flow condition. A bladder type diaphragm
tank shall be installed with a pre-charge pressure of 70% of system set-point. The tank shall
be piped to the discharge manifold or system piping downstream of the pump system. When
low flow is detected (signal from flow switch or meter), the system controller shall increase
pump speed until the discharge pressure reaches the stop pressure (system set-point plus
50% of programmed on/off band). The pump shall remain off until the discharge pressure
reaches the start pressure (system set-point minus 50% of programmed on/off band). The
pump shall remain in the energy saving on/off mode during low flow indication. When low
flow is no longer present (low flow indication ceases), the pump(s) shall resume constant
pressure operation.
It shall be possible to change from the standard low flow stop to the optional low flow stop (and
vice-versa) via the user interface.
2.8
SYSTEM CONSTRUCTION
A. The suction and discharge manifolds shall be constructed of 316 stainless steel. Manifold
connection sizes shall be as follows:
3 inch and smaller:
4 inch through 8 inch:
10 inch and larger:
Male NPT threaded
ANSI Class 150 rotating flanges
ANSI Class 150 flanges
B. Pump Isolation valves shall be provided on the suction and discharge of each pump. Isolation
valve sizes 2 inch and smaller shall be nickel plated brass full port ball valves. Isolation valve
sizes 3 inch and larger shall be a full lug style butterfly valve. The valve disk shall be of stainless
steel. The valve seat material shall be EPDM and the body shall be cast iron, coated internally
and externally with fusion-bonded epoxy.
B. A spring-loaded non-slam type check valve shall be installed on the discharge of each pump.
The valve shall be a wafer style type fitted between two flanges. The head loss through the valve
shall not exceed 5 psi at the pump design capacity. Check valves 1-1/2” and smaller shall have a
POM composite body and poppet, a stainless steel spring with EPDM or NBR seats. Check
valves 2” and larger shall have a body material of stainless steel or epoxy coated iron (fusion
bonded) with an EPDM or NBR resilient seat. Spring material shall be stainless steel. Disk shall
be of stainless steel or leadless bronze.
C. For systems that require a diaphragm tank, a minimum diaphragm tank connection size of ¾”
shall be provided on the discharge manifold.
D. A pressure transducer shall be factory installed on the discharge manifold (or field installed as
specified on plans). Systems with positive inlet gauge pressure shall have a factory installed
pressure transducer on the suction manifold for water shortage protection. Pressure transducers
shall be made of 316 stainless steel. Transducer accuracy shall be +/- 1.0% full scale with
hysteresis and repeatability of no greater than 0.1% full scale. The output signal shall be 4-20
mA with a supply voltage range of 9-32 VDC.
E. A bourdon tube pressure gauge, 2.5 inch diameter, shall be placed on the suction and discharge
manifolds. The gauge shall be liquid filled and have copper alloy internal parts in a stainless steel
case. Gauge accuracy shall be 2/1/2 %. The gauge shall be capable of a pressure of 30%
above it’s maximum span without requiring recalibration.
BoosterpaQ Hydro MPC F Guide Specification, Page 8 of 9
F. Systems with a flooded suction inlet or suction lift configuration shall have a factory installed
water shortage protection device on the suction manifold.
G. The base frame shall be constructed of corrosion resistant 304 stainless steel. Rubber vibration
dampers shall be fitted between each pump and baseframe to minimize vibration.
H. Depending on the system size and configuration, the control panel shall be mounted in one of the
following ways:
On a 304 stainless steel fabricated control cabinet stand attached to the system skid
On a 304 stainless steel fabricated skid, separate from the main system skid
On it’s own base (floor mounted with plinth)
2.9
TESTING
A. The entire pump station shall be factory performance tested as a complete unit prior to shipment.
Job-site programming shall be entered into the controller prior to shipment (details of installation
requirements shall be communicated to the pump system manufacturer). A verified performance
test report shall be made available from the system manufacturer.
B. The system shall undergo a hydrostatic test of 350 psig for a minimum of 15 minutes prior to
shipment.
3.0
WARRANTY
A. The warranty period shall be a non-prorated period of 24 months from date of installation, not to
exceed 30 months from date of manufacture.
BoosterpaQ Hydro MPC F Guide Specification, Page 9 of 9